Introduction Words like Industry 4.0 and the Internet of Things (IoT) seem to be everywhere these days. But what do they mean for a rugged industry

Transcription

1 ANYTIME, ANYWHERE Matt Morrissey, Siemens, Canada, explores the use of the Internet of Things to achieve total automation transparency, and to provide complete access at all times.

2 Introduction Words like Industry 4.0 and the Internet of Things (IoT) seem to be everywhere these days. But what do they mean for a rugged industry like cement? Isn t there already more than enough to do: s to answer, maintenance to attend to, customers to manage, measurements to validate the list goes on. So how can even more data actually save time?

3 Critical process information can be accessed on any device: tablet, phone, or computer. Imagine knowing the specifications happening here, no matter where you are. Integrating process information into a facility allows more time to plan for enhancements and other improvements. A day in the life of a cement plant manager You are in your cement plant s adjacent quarry and want to check the efficiency of one of the primary crushers. You pull out your cell phone to see the flow rate of the belt scale good, it is right where it should be. On the way back from the quarry, you get a call that a filter bag has ripped and an acoustic sensor has detected particulate in one of the plant s baghouses. You get your phone out again, after coming to a safe stop, and confirm this, based on the alarm from one of your Sitrans AS100 acoustic sensors that is over range. You tell the repair crew to fix the filter and then continue driving back to the plant. You pass the stacker-reclaimer and watch as the growing pile is being monitored by a Siemens Echomax XPS-15 transducer and MultiRanger ultrasonic controller. You take out your phone to check the pile s level, confirming that it matches your rough eye measurement of it. Moving on to chemical storage, you notice an older rusty pipe with a Sitrans FC430 coriolis flowmeter on it. You connect to the flowmeter using your smart device, checking its value and comparing it to the trend in the device s data log. Looks like the flow isn t being restricted just yet, so replacing the pipe can wait for a rainy day. Another call from the control room: temperature sensors have indicated that the kiln is cooling down! That is not good. Productivity of the whole plant would be affected if something happened there. A quick look at the system via your phone shows that one of the pressure transmitters on the fuel feed is also below spec. Perhaps the fuel line is clogged, or worse, maybe the pressure has dropped due to a leak somewhere. You and your crew head there straight away. As the crew fixes the fuel line, you finally head back to the control room. On the way in you remember that a train delivery is coming later today, so you use your phone to access the finished cement silo, double checking the level from the silo s Sitrans LR560 radar level transmitter. You know that ten rail cars will hold about 50% of the silo and the measurement shows the level is above 75%. After all that, it is probably time for a coffee break, don t you think? Knowledge any time, from everywhere Complete knowledge of what is happening at a plant, and with each instrument, at all times, is key. Much more than a traditional distributed control system (DCS), Simatic PCS 7 combines a

4 SIMATIC PCS 7 performance you trust Web Client - OS - Maintenance - Information ERP Ethernet, Office LAN Front Firewall Optionale Server - Web Server - OpenPCS 7 - Information Server OS Server, Batch Server, Route Control Server, Maintenance Server, Process Historian Operator System (OS) Single Station Mobiler Client Industrial Wireless LAN OS Client 427D OS/Batch/Route Control/Maintenance Clients Industrial Ethernet Netzwerkdrucker Optionale Clients - Simulation mit SIMIT - MES/MIS mit SIMATIC IT - Plant Lifecycle Management COMOS Back Firewall Management Console Engineering Stationen PCS 7 BOX PCS 7 AS mec RTX mit S7-300 I/Os Standard- Hochverfügbare Sicherheitsgerichtete ET 200pro Kompaktsysteme Embedded Zone 2 Zone 1 Zone 2 Zone 1 Ex-Bedien-terminal single/redundant F-Baugruppen Wireless HART MTA, Ex-I/O, HART -is Zone 1 Wägesysteme ET 200SP ET 200SP ET 200iSP ET 200iSP Y-Link AS-Interface Modbus, serielle Kopplung SCALANCE X Switch IE/PB Link Gasanalyse PA Link/FF Link PA Link PROFIBUS PA Integriertes Energiemanagement IE/PB Link + DP/PA Koppler PROFIBUS PA is SIMOCODE pro for AFS PA/FF H1 is ET 200pro PA Link/FF Link Integrierte Antriebe PA/FF H1 is ET 200S G_PCS7_XX_00388 Siemens Totally Integrated Automation makes it possible to merge many monitoring systems together in one plant, providing a complete solution for automation. The combination of reliable process instruments and Simatic PDM with PCS 7 helps take the worries away from operating stress, allowing real time readings on a device, wherever needed. Siemens process instruments, including level, pressure, temperature, flow, and weighing, are the ears and eyes of the process. scalable architecture with powerful engineering tools and a wide variety of additional functions, such as alarm management, process safety, and asset management, all of which can be integrated seamlessly into the existing environment. CEMAT, based on Simatic PCS 7, represents a complete philosophy on how to operate a cement plant, how to make diagnoses to keep downtimes to a minimum in the event of a plant problem, and how to interconnect drives, MCCs, power devices, and process instrumentations from the plant. Simatic PCS 7 distributed control system from Siemens provides transparency for the automation system for cement plant managers or those in any other industry through a phone, tablet, or PC via a webserver with a process overview interface. Simatic PDM is used on a tablet or PC via a web server for complete access to the instruments for diagnosis or process variables. l Checking the measurements of all belt scales in a quarry from the comfort of a truck on a cold winter day? l Resetting the totalisers on two coriolis flowmeters on grinding additives without walking past a seemingly endless series of pipes? l Lowering the 100% level on a 15 level instruments to help reduce inventory cost? l Changing the scaling of submerged pressure transmitters without leaving the control room?

5 Real-time, dependable monitoring For remote operating and monitoring of Sitrans instruments or other products, a tablet or PC with web access can access Simatic PDM via a web server. This gives direct access to any device on the bus, using standard industrial protocols and an EDD. If a tablet or smart phone is used instead of a normal work station, it is mobile and can connect to the network over wireless. Complete visualisation of the process and measurements are available for quick and easy access. For example, in a meeting when a tough question comes up about inventory or maybe about an issue in production. It can be checked in real time and an answer can be provided by accessing the data virtually. Partnering with process instruments Data, however, no matter how readily available, is only as good as the sensors it is coming from. Take the Heracles cement plant in Greece, which uses Siemens level measurement in its raw material silos. We can now rely on the level system from Siemens to provide us with the automated control we need for efficient raw mill feeding, said the company s technical consultant at the plant. Chinese cement producer Longyuan Construction Anhui Cement Company Ltd. uses Siemens weighing technology to ensure accuracy in its custody transfers. After installing Siemens belt scales, we saw a real difference in our current operations, said Longyuan Construction s director of engineering. The electrical supervisor at St. Marys Cement in Bowmanville, Canada, which has used a host of Siemens instrumentation throughout its plant for decades, when asked about these devices, stated: they just work. Even in the age of IOT and the digital factory, it is still vital that a plant s machinery and automation just work. Without accurate, reliable, and rugged process instrumentation and analytics, that day-in-the-life, as described previously, is made much more difficult, at best, or nearly impossible at worst. But the seamless integration of sensors and smart device provides the ability to deal with issues before they become problems. Industry 4.0 and automation with smart devices Siemens instrumentation and automation cannot solve all of the world s problems, but Simatic PCS 7 with PDM makes some easier to deal with. With the advent of Industry 4.0, this option for transparency and connectivity takes process instrumentation to a different level, giving unparalleled control and access.